Sight Glass Reflection Sensing for Refrigerant Phase Detection
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Solution Overview
Problem
Existing refrigeration systems lack an efficient and automated method to monitor the liquid and vapor phases of refrigerants in real-time, relying on manual observation through sight glasses, which is inefficient and prone to human error.
Innovation Solution
A device comprising LEDs, light sensors, and a micro-controller that analyze the intensity of reflected light to determine the relative quantities of liquid and vapor phases, using a housing with a reflective surface and circuit components to output digital signals for automated phase detection and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual observation through sight glasses is used to monitor refrigerant phases, then the device complexity is low, but the productivity and reliability are reduced due to inefficiency and human error
Solution Approach 1:
The patent replaces the manual mechanical observation method with an automated optical detection system. LEDs emit light through the sight glass, and photodetectors automatically measure light transmission to determine refrigerant phase, eliminating the need for human visual inspection while providing continuous real-time monitoring.
Solution Approach 2:
The system performs self-diagnosis and automatic phase detection without requiring operator intervention. The microcontroller automatically processes photodetector signals, compares them against stored reference values for liquid and vapor states, and generates phase identification outputs autonomously.
2Reliability
If automated light-based detection is implemented, then the productivity and reliability improve, but the device complexity increases due to additional circuit components
Solution Approach 1:
The patent introduces intermediate components that facilitate the detection process: the sight glass serves as an optical window that allows light transmission while containing the refrigerant, and the reflective surface within the housing directs LED light toward the photodetectors. These intermediaries enable reliable automated detection without requiring direct contact with the refrigerant.
Solution Approach 2:
The system utilizes optical property changes that occur with refrigerant phase transitions. Different phases (liquid vs. vapor) have different optical densities and light transmission characteristics. The photodetectors measure these optical variations, and the microcontroller interprets them to reliably distinguish between liquid and vapor states.
3Measurement precision
If multiple LEDs and photodetectors are used for accurate phase detection, then the measurement precision improves, but the manufacturing complexity increases
Solution Approach 1:
The optical detection system is divided into discrete, modular components: individual LEDs positioned at specific angles, separate photodetectors for different measurement functions, and distinct circuit board sections. This segmentation allows each component to be manufactured and tested independently, then assembled into the complete device, improving overall manufacturability.
Solution Approach 2:
The sight glass serves multiple functions simultaneously: it acts as a viewing window for manual inspection, a structural component of the housing, and an optical element that guides light from LEDs to photodetectors. The reflective surface within the housing also serves dual purposes by directing light and providing structural support. This multi-functionality reduces the total number of separate parts needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Provides real-time, automated monitoring of refrigerant phases, enhancing system efficiency by reducing human error and enabling precise control of refrigerant states, thereby optimizing system operations.
Implementation Method 1
Reflections of the LEDs from the interior reflective surface are detected by the light sensor
Data Source
AI summary
A liquid and vapor recognition device is described herein comprising a housing configured to connect to a sight port including a sight glass and including an interior reflective surface, a first circuit component comprising a plurality of light emitting diodes (LEDs) and a light sensor, the first circuit component being mounted within the housing proximate the sight glass with the interior reflective surface of the housing disposed opposite the LEDs, and a second circuit component mounted proximate the first circuit component, the second circuit component containing a plurality of analog to digital converters (ADCs). Reflections of the LEDs from the interior reflective surface are detected by the light sensor, and the light sensor communicates with the plurality of ADCs, which output a digital signal indicative of the intensity of the reflected light.